Processed Biomass Pellets from Organic-Carbon-Containing Feedstock

ABSTRACT

A renewable processed biomass pellet composition made with a pelletizing sub-system from a processed organic-carbon-containing feedstock made with a beneficiation sub-system is described. Renewable biomass feedstock passed through a beneficiation sub-system to reduce water content to below at least 20 wt % and water-soluble intracellular salt reduction of at least 60% from that of unprocessed organic-carbon-containing feedstock on a dry basis. The processed feedstock is introduced into a pelletizing sub-system to result in renewable processed biomass pellets having an energy density of at least 17 MMBTU/ton (20 GJ/MT) a water content of less than 20 wt %, and water-soluble intracellular salt content that is decreased by at least 60 wt % on a dry basis for the processed organic-carbon-containing feedstock from that of the unprocessed organic-carbon-containing feedstock, and made with 40% less energy than expended to make current biomass pellets.

FIELD OF THE INVENTION

The present invention relates generally to the production of solidbiomass fuel from an organic-carbon-containing feedstock.

BACKGROUND OF THE INVENTION

The vast majority of fuels are distilled from crude oil or obtained fromnatural gas pumped from limited underground reserves, or mined fromcoal. As the earth's crude oil supplies become more difficult andexpensive to collect and there are growing concerns about theenvironmental effects of coal other than clean anthracite coal, theworld-wide demand for energy is simultaneously growing. Over the nextten years, depletion of the remaining world's easily accessible crudeoil reserves, natural gas reserves, and low-sulfur bituminous coalreserves will lead to a significant increase in cost for fuel obtainedfrom crude oil, natural gas, and coal.

The search to find processes that can efficiently convert biomass tofuels and by-products suitable for transportation and/or heating is animportant factor in meeting the ever-increasing demand for energy. Inaddition, processes that have solid byproducts that have improvedutility are also increasingly in demand.

Biomass is a renewable organic-carbon-containing feedstock that containsplant cells and has shown promise as an economical source of fuel.However, this feedstock typically contains too much water andcontaminants such as water-soluble salts to make it an economicalalternative to common sources of fuel such as coal, petroleum, ornatural gas.

Historically, through traditional mechanical/chemical processes, plantswould give up a little less than 25 weight percent of their moisture.And, even if the plants were sun or kiln-dried, the natural and man-madechemicals and water-soluble salts that remain in the plant cells combineto create corrosion and disruptive glazes in furnaces. Also, theremaining moisture lowers the heat-producing million British thermalunits per ton (MMBTU per ton) energy density of the feedstock thuslimiting a furnace's efficiency. A BTU is the amount of heat required toraise the temperature of one pound of water one degree Fahrenheit, and 1MM BTU/ton is equivalent to 1.163 Giga joules per metric tone (GJ/MT.Centuries of data obtained through experimentation with a multitude ofbiomass materials all support the conclusion that increasingly largerincrements of energy are required to achieve increasingly smallerincrements of bulk density improvement. Thus, municipal waste facilitiesthat process organic-carbon-containing feedstock, a broader class offeedstock that includes materials that contain plant cells, generallyoperate in an energy deficient manner that costs municipalities money.Similarly, the energy needed to process agricultural waste, alsoincluded under the general term of organic-carbon-containing feedstock,for the waste to be an effective substitute for coal or petroleum arenot commercial without some sort of governmental subsidies and generallycontain unsatisfactory levels of either or both water or water-solublesalts. The cost to suitably transport and/or prepare such feedstock in alarge enough volume to be commercially successful is expensive andcurrently uneconomical. Also, the suitable plant-cell-containingfeedstock that is available in sufficient volume to be commerciallyuseful generally has water-soluble salt contents that result in adversefouling and contamination scenarios with conventional processes.Suitable land for growing a sufficient amount of energy crops to makeeconomic sense typically are found in locations that result in highwater-soluble salt content in the plant cells, i.e., often over 4000mg/kg on a dry basis.

Attempts have been made to prepare organic-carbon-containing feedstockas a solid renewable fuel, coal substitute, or binders for the making ofcoal aggregates from coal fines, but these have not been economicallyviable as they generally contain water-soluble salts that can contributeto corrosion, fouling, and slagging in combustion equipment, and havehigh water content that reduces the energy density to well below that ofcoal in large part because of the retained moisture. However, thereremains a need for biomass or biochar as it is a clean renewable sourceof solid fuel if it could be made cost-effectively with a moresubstantial reduction in its content of water and water-soluble salt foruse as coal substitutes or as high energy binders with coal fines.

Solid byproducts with improved beneficial properties are an importantfactor in meeting the ever-increasing demand for energy. The presentinvention fulfills these needs and provides various advantages over theprior art.

SUMMARY OF THE INVENTION

Embodiments of the present invention are directed to a composition fromrenewable, unprocessed organic-carbon-containing feedstock and aprocess. The composition is a processed biomass pellet composition thatcomprises a processed organic-carbon-containing feedstock withcharacteristics that include an energy density of at least 17 MMBTU/ton(20 GJ/MT), a water content of less than 20 wt %, and a water-solubleintracellular salt content that is decreased more than 60 wt % on a drybasis for the processed organic-carbon-containing feedstock from that ofunprocessed organic-carbon-containing feedstock. The processed biomasspellet is made with a system configured to convert renewable unprocessedorganic-carbon-containing feedstock into the processedorganic-carbon-containing feedstock with a beneficiation sub-system, andinto the processed biomass pellets with a pelletizing sub-system that ismade with 40% less energy than expended to make an unprocessed biomasspellet.

The process of making the processed biomass pellet composition comprisesthree steps. The first step is to input into a system, comprising afirst and a second subsystem, a renewable unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils. The second stepis to pass the unprocessed organic-carbon-containing feedstock throughthe first sub-system, a beneficiation sub-system process, to result inprocessed organic-carbon-containing feedstock having a water content ofless than 20 wt % and a water soluble intracellular salt content that isreduced by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the unprocessedorganic-carbon-containing feedstock. The third step is to pass theprocessed organic-carbon-containing feedstock through the secondsub-system, a pelletizing sub-system process, to result in processedbiomass pellets, a solid renewable fuel composition having an energydensity of at least 17 MMBTU/ton (20 GJ/MT) a water content of less than10 wt %, and water-soluble intracellular salt that is decreased by atleast 60 wt % on a dry basis for the processed organic-carbon-containingfeedstock from that of the unprocessed organic-carbon-containingfeedstock, and made with 40% less energy than expended to make currentunprocessed biomass pellets.

The invention is a processed biomass pellet that is a suitable cleancoal substitute for devices that use coal as a feedstock to generateheat such as, for example, coal-fired boilers used to make electricity.The low salt content of the processed biomass pellets substantiallyreduces adverse corrosive wear and maintenance cleaning of the devicesthat is typical today. The uniform low water content and uniform, highenergy density of the beneficiated organic-carbon-containing feedstockused to make the processed biomass pellets allow for a wide variety ofrenewable organic-carbon-containing feedstock to be used in pelletizingsection of the process in a cost efficient manner. During thebeneficiation section of the process, the substantial reduction ofwater-soluble salts reduces the adverse results that occur with thesubsequent use of the processed organic-carbon-containing feedstock. Inaddition, energy needed to remove water from unprocessedorganic-carbon-containing feedstock described above to a content ofbelow 20 wt % and a substantial amount of the water-soluble salt withthe invention is significantly less than for conventional processes. Insome embodiments, the total cost per weight of the beneficiatedfeedstock is reduced by at least 60% of the cost to perform a similartask with known mechanical, physiochemical, or thermal processes toprepare renewable organic-carbon-containing feedstock for use insubsequent fuel making operations such as an oxygen-deficient thermalsub-system. In addition, processed biomass pellets can be made with 40%less energy than expended to make current unprocessed biomass pellets.

The above summary is not intended to describe each embodiment or everyimplementation of the present invention. Advantages and attainments,together with a more complete understanding of the invention, willbecome apparent and appreciated by referring to the following detaileddescription and claims taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram of a typical plant cell with an exploded view of aregion of its cell wall showing the arrangement of fibrils,microfibrils, and cellulose in the cell wall.

FIG. 2 is a diagram of a perspective side view of a part of two fibrilsin a secondary plant cell wall showing fibrils containing microfibrilsand connected by strands of hemicellulose and lignin

FIG. 3 is a diagram of a cross-sectional view of a section of bagassefiber showing where water and water-soluble salts reside inside andoutside plant cells.

FIG. 4 is a diagram of a side view of an embodiment of a reactionchamber in a beneficiation sub-system.

FIG. 5A is a diagram of the front views of various embodiments ofpressure plates in a beneficiation sub-system.

FIG. 5B is a perspective view of a close-up of one embodiment of apressure plate shown in FIG. 5A.

FIG. 5C is a diagram showing the cross-sectional view down the center ofa pressure plate with fluid vectors and a particle of pith exposed tothe fluid vectors.

FIG. 6A is a graphical illustration of the typical stress-strain curvefor lignocellulosic fibril.

FIG. 6B is a graphical illustration of pressure and energy required todecrease the water content and increase the bulk density of typicalorganic-carbon-containing feedstock.

FIG. 6C is a graphical illustration of the energy demand multiplierneeded to achieve a bulk density multiplier.

FIG. 6D is a graphical illustration of an example of a pressure cyclefor decreasing water content in an organic-carbon-containing feedstockwith an embodiment of the invention tailored to a specific theorganic-carbon-containing feedstock.

FIG. 7 is a table illustrating the estimated energy consumption neededto remove at least 75 wt % water-soluble salt fromorganic-carbon-containing feedstock and reduce water content from 50 wt% to 12 wt % with embodiments of the beneficiation sub-system of theinvention compared with known processes.

FIG. 8 is a diagram of a side view of an embodiment of a beneficiationsub-system having four reaction chambers in parallel, a pretreatmentchamber, and a vapor condensation chamber.

FIG. 9 is a diagram of a process to make pellets from unprocessedorganic-carbon-containing feedstock.

FIG. 10 is a block diagram of an embodiment of a process for passingunprocessed organic-carbon-containing feedstock through a beneficiationsub-system to create a processed organic-carbon-containing feedstockwith a water content of less than 20 wt % and a water-soluble saltcontent that is decreased by more than 60 wt % on a dry basis for theprocessed organic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock.

FIG. 11 is a block diagram of an embodiment of a process for passingunprocessed organic-carbon-containing feedstock through a beneficiationsub-system to create a processed organic-carbon-containing feedstockwith a water content of less than 20 wt %, a water-soluble salt contentthat is decreased by more than 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock, and an energy cost of removing thewater-soluble salt and water that is reduced to less than 60% of thecost per weight of similar removal from known mechanical, knownphysiochemical, or known thermal processes.

FIG. 12 is a table showing relative process condition ranges and waterand water-soluble salt content for three types oforganic-carbon-containing feedstock used in the beneficiationsub-system.

While the invention is amenable to various modifications and alternativeforms, specifics have been shown by way of example in the drawings andwill be described in detail below. It is to be understood, however, thatthe intention is not to limit the invention to the particularembodiments described. On the contrary, the invention is intended tocover all modifications, equivalents, and alternatives falling withinthe scope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

The processed biomass pellets of the invention is a renewable solid fuelmade from passing beneficiated processed organic-carbon-containingfeedstock through a pelletizing system. The processed biomass pelletsare similar to sub-bituminous coal in energy density. The processedbiomass pellets of the invention have the advantages of coming from arenewable source, i.e., agricultural and plant materials, without theburdens of current biomass processes that are inefficient and removeless if any of the salt found in unprocessed renewable biomass. Thereare several aspects of the invention that will be discussed: processedbiomass pellets, unprocessed renewable organic-carbon-containingfeedstock, beneficiation sub-system, pelletizing sub-system,beneficiation sub-system process, and pelletizing sub-system process.

Processed Biomass Pellets

Biomass pellets made from renewable organic-carbon-containing feedstockis referred to as processed biomass pellets in this document. Theprocessed biomass pellet of the invention comprises a solid carbon fuelcomprising less than 20 wt % water, and water-soluble intracellular saltthat is less than 60 wt % on a dry basis that of unprocessedorganic-carbon-containing feedstock. The processed biomass pellet ismade from unprocessed organic-carbon-containing feedstock that isconverted into a processed organic-carbon-containing feedstock in abeneficiation sub-system, and that is then passed through a pelletizingsub-system. As used in this document, processed biomass pellets are asolid product of beneficiated organic-carbon-containing feedstock thatis subsequently pelletized. Organic-carbon-containing feedstock used tomake the processed biomass of the invention can contain mixtures of morethan one renewable feedstock.

Coal has inorganic impurities associated with its formation undergroundover millions of years. The inorganic impurities are not combustible,appear in the ash after combustion of coal in such situations as, forexample boilers, and contribute to air pollution as the fly ashparticulate material is ejected into the atmosphere followingcombustion. The inorganic impurities result mainly from clay mineralsand trace inorganic impurities washed into the rotting biomass prior toits eventual burial. An important group of precipitating impurities arecarbonate minerals. During the early stages of coat formation, carbonateminerals such as iron carbonate are precipitated either as concretions(hard oval nodules up to tens of centimeters in size) or as infillingsof fissures in the coal, Impurities such as sulfur and trace elements(including mercury, germanium, arsenic, and uranium) are chemicallyreduced and incorporated during coal formation. Most sulfur is presentas the mineral pyrite (FeS₂), which may account for up to a few percentof the coal volume. Burning coal oxidizes these compounds, releasingoxides of sulfur (SO, SO₂, SO₃, S₇O₇, S₆O₇, etc.), notoriouscontributors to acid rain. The trace elements (including mercury,germanium, arsenic, and uranium) were significantly enriched in the coalare also released by burning it, contributing to atmospheric pollution.

In contrast, the processed biomass pellets of the invention are cleanerthan coal. The impurities discussed above are not present in anysignificant amount. In particular, processed biochar containssubstantially no sulfur, Some embodiments have a sulfur content of lessthan 1000 mg/kg (0.1 wt %) or less than 1000 parts per million (ppm),some of less than 100 mg/kg (100 ppm, some of less than 10 mg/kg (10ppm). In contrast coal has significantly more sulfur. The sulfur contentin coal ranges of from 4000 mg/kg (0.4 wt %) to 40,000 mg/kg (4 wt %)and varies with type of coal. The typical sulfur content in anthracitecoal is from 6000 mg/kg (0.6 wt %) to 7700 mg/kg (0.77 wt %). Thetypical sulfur content in bituminous coal is from 7000 mg/kg (0.7 wt %)to 40.000 mg/kg (4 wt %). The typical sulfur content in lignite coal isabout 4000 mg/kg (0.4 wt %). Anthracite coal is too expensive forextensive use in burning. Lignite is poor quality coal, with a lowenergy density or BTU/wt.

In addition, processed biomass pellets have substantially no nitrate,arsenic, mercury or uranium. Some embodiments have a nitrate content ofless than 500 mg/kg (500 ppm), some of less than 150 mg/kg (150 ppm),versus a nitrate content in coal of typically over 20,000 mg·kg (2 wt%), Some embodiments have a arsenic content of less than 2 mg/kg (2ppm), some of less than 1 mg/kg (1 ppm), some less than 0.1 mg/kg or 100parts per billion (ppb), and some less than 0.01 mg/kg (10 ppb) versus aarsenic content in coal of from over 1 mg/kg to over 70 mg/kg (1 ppm to70 ppm). Some embodiments have a mercury content that is negligible,i.e., less than 1 microgram/kg (1 ppb), versus mercury content in coalof from 0.02 mg/kg (20 ppb) to 0.3 mg/kg (300 ppb). Similarly, someembodiments have a uranium content that is also negligible, i.e., lessthan 1 microgram/kg ppb), versus a uranium content in coal of from 20mg/kg (20 ppm) to 315 mg/kg (315 ppm) with an average of about 65 mg/kg(ppm) and the uranium content in the ash from the coal with an averageof about 210 mg/kg (210 ppm).

Other forms of char are also known. Some of these chars include, forexample, char made by the pyrolysis of biomass, also known as charcoal.Charcoal has an energy density of about 26 MMBTU/tom (30 GJ/MT) andcontains all of the water-soluble salt residues found in the startingbiomass used to make the charcoal. Charcoal has various uses including,for example, a combustible fuel for generating heat for cooking andheating, as well as a soil amendment to supply minerals for fertilizingsoils used for growing agricultural and horticultural products. Char hasalso been made by passing biomass through an open microwave oven similarto a bacon cooker that is exposed to the external atmosphere containingoxygen and contains pores with a variance similar to that made by athermal process that has a liquid phase. In char made by thermal heat orinfrared radiation, the heat is absorbed on the surface of anyorganic-carbon-containing feedstock and then is re-radiated to the nextlevel at a lower temperature. This process is repeated over and overagain until the thermal radiation penetrates to the inner most part ofthe feedstock. All the material in the feedstock absorbs the thermalradiation at its surfaces and different materials that make up thefeedstock absorb the IR at different rates. A delta temperature ofseveral orders of magnitude can exist between the surface and the innermost layers or regions of the feedstock. As a result, the solidorganic-carbon-containing feedstock locally passes through a liquidphase before it is volatilized. This variation in temperature may appearin a longitudinal direction as well as radial direction depending on thecharacteristics of the feedstock, the rate of heating, and thelocalization of the heat source. This variable heat transfer from thesurface to the interior of the feedstock can cause cold and hot spots,thermal shocks, uneven surface and internal expansion cracks,fragmentation, eject surface material and create aerosols. All of thiscan result in microenvironments that cause side reactions with thecreation of many different end products. These side reactions are notonly created in the feedstock but also in the volatiles that evaporatefrom the feedstock and occupy the vapor space in the internal reactorenvironment before being collected.

A common thermal process, pyrolysis, produces biochar, liquids, andgases from biomass by heating the biomass in a low/no oxygenenvironment. The absence of oxygen prevents combustion. Typical yieldsare 60% bio-oil, 20% biochar, and 20% volatile organic gases. Hightemperature pyrolysis in the presence of stoichiometric oxygen is knownas gasification, and produces primarily syngas. By comparison, slowpyrolysis can produce substantially more char, on the order of about50%.

Another thermal process is a sublimation process that produces biocharand gases from biomass in a low/no oxygen environment. The absence ofoxygen also prevents combustion. Typical yields are 70% fuel gas and 30%biochar. Sublimation can occur in a vertical manner that lends itself toheavier/denser biomass feedstock such as, for example, wood and ahorizontal manner that lends itself to lighter/less dense biomassfeedstock such as, for example, wheat straw.

In contrast to thermal processes, the process to make char by microwaveradiation uses heat that is absorbed throughout theorganic-carbon-containing feedstock. The process uses microwaveradiation from the oxygen-starved microwave process system. Withmicrowave radiation, the solid part of the feedstock is nearlytransparent to the microwave radiation and most of the microwaveradiation just passes through. In contrast to the small absorption crosssection of the solid feedstock, gaseous and liquid water strongly absorbthe microwave radiation increasing the rotational and torsionalvibrational energy of the water molecules. Therefore, the gaseous andliquid water that is present is heated by the microwaves, and thesewater molecules subsequently indirectly heat the solid feedstock. Thusany feedstock subjected to the microwave radiation field is exposed tothe radiation evenly, inside to outside, no matter what the physicaldimensions and content of the feedstock. With microwaves, the radiationis preferentially absorbed by water molecules that heat up. This heat isthen transferred to the surrounding environment resulting in thefeedstock being evenly and thoroughly heated.

In all of the above processes, water-soluble salt that is in allrenewable organic-carbon-containing feedstock is not removed This hasthe adverse effect of increasing ash content in combusted char andincreasing wear and maintenance costs from corrosion and slagging, adeposition of a viscous residue of impurities during combustion. Incontrast, the process to make the processed biochar of the inventionused a beneficiation sub-system to process the unprocessedorganic-carbon—containing feedstock to remove most of the water andwater-soluble salts, and an oxygen-deficient thermal sub-system toconvert the processed organic-carbon-containing feedstock into aprocessed biochar.

In contrast, the processed biomass pellets of the invention contain muchless water-soluble salt than that of currently known biomass pellets andknown biochar. The use of a processed organic-carbon-containingfeedstock rather than an unprocessed organic-carbon-containing feedstockused by the above known biomass and biochar result in significantimprovements at a time when the impurities in coal and current biomassis receiving negative attention.

The processed biomass pellets of the invention have several improvedcharacteristics when compared to a biomass pellets that use unprocessedorganic-carbon-containing feedstock. First, the processed biocharcontains significantly less salt than that produced from currentprocesses that use similar unprocessed organic-carbon-containingfeedstock. The salt in the processed organic-carbon-containing feedstockand thus in the resulting processed biochar is reduced by at least 60 wt% on a dry basis for the processed organic-carbon-containing feedstockfrom that of the salt content of the unprocessedorganic-carbon-containing feedstock. As a result, the fixed carbon ofthe resulting processed biomass pellets is higher and the ash content islower because there is less salt that forms ash during combustion. Also,the adverse effect of salt in the boiler is reduced, wear is slower, andmaintenance cleaning of the equipment is less often and less arduous.

Second, the processed biochar has a high energy density, approachingthat of sub-bituminous coal. The energy density is at least 17 MMBTU/ton(20 GJ/MT). In contrast, the energy density of biomass pellets fromunprocessed organic-carbon-containing feedstock is no more than between10 MMBTU/ton (12 GJ/MT) and 12 MMBTU/ton (14 GJ/MT).

Third, the processed biochar contains little if any pollutants normallyassociated with coal. These pollutants include, for example, mercury(neurotoxin), arsenic (carcinogen), and SxOy when the coal is combusted.Processed biochar contains less than 0.1 wt % of any one of the aboveimpurities, some embodiments contain less than 0.01 wt %, some less than0.001 wt %, some less than 0.0001 wt %.

In some embodiments of the inventions, organic-carbon-containingfeedstock used to make the processed biomass pellets of the inventioncan contain mixtures of more than one renewable feedstock when theprocessed organic-carbon-containing feedstock is made to havesubstantially uniform energy densities regardless of the type oforganic-carbon-containing feedstock used.

Unprocessed Organic-Carbon-Containing Feedstock

Cellulose bundles, interwoven by hemicellulose and lignin polymerstrands, are the stuff that makes plants strong and proficient inretaining moisture. Cellulose has evolved over several billion years toresist being broken down by heat, chemicals, or microbes. In a plantcell wall, the bundles of cellulose molecules in the microfibrilsprovide the wall with tensile strength. The tensile strength ofcellulose microfibrils is as high as 110 kg/mm², or approximately 2.5times that of the strongest steel in laboratory conditions. Whencellulose is wetted, as in the cell walls, its tensile strength declinesrapidly, significantly reducing its ability to provide mechanicalsupport. But in biological systems, the cellulose skeleton is embeddedin a matrix of pectin, hemicellulose, and lignin that act aswaterproofing and strengthening material. That makes it difficult toproduce fuels from renewable cellulose-containing biomass fast enough,cheap enough, or on a large enough scale to make economical sense. Asused herein, organic-carbon-containing material means renewableplant-containing material that can be renewed in less than 50 years andincludes plant material such as, for example herbaceous materials suchas grasses, energy crops, and agricultural plant waste; woody materialssuch as tree parts, other woody waste, and discarded items made fromwood such as broken furniture and railroad ties; and animal materialcontaining undigested plant cells such as animal manure.Organic-carbon-containing material that is used as a feedstock in aprocess is called an organic-carbon-containing feedstock

Unprocessed organic-carbon-containing material, also referred to asrenewable biomass, encompasses a wide array of organic materials asstated above. It is estimated that the U.S. alone generates billions oftons of organic-carbon-containing material annually. As used in thisdocument, beneficiated organic-carbon-containing feedstock is processedorganic-carbon-containing feedstock where the moisture content has beenreduced, a significant amount of dissolved salts have been removed, andthe energy density of the material has been increased. This processedfeedstock can be used as input for processes that make severalenergy-producing products, including, for example, liquid hydrocarbonfuels, solid fuel to supplant coal, and synthetic natural gas.

As everyone in the business of making organic-carbon-containingfeedstock is reminded, the energy balance is the metric that mattersmost. The amount of energy used to beneficiate organic-carbon-containingfeedstock and, thus, the cost of that energy must be substantiallyoffset by the overall improvement realized by the beneficiation processin the first place. For example, committing 1000 BTU to improve the heatcontent of the processed organic-carbon-containing feedstock by 1000BTU, all other things being equal, does not make economic sense unlessthe concurrent removal of a significant amount of the water-soluble saltrenders previously unusable organic-carbon-containing feedstock usableas a fuel substitute for some processes such as boilers.

As used herein, organic-carbon-containing feedstock comprises freewater, intercellular water, intracellular water, intracellularwater-salts, and at least some plant cells comprising cell walls thatinclude lignin, hemicellulose, and cellulosic microfibrils withinfibrils. In some embodiments, the water-soluble salt content of theunprocessed organic-carbon-containing feedstock is at least 4000 mg/kgon a dry basis. In other embodiments the salt content may be more than1000 mg/kg, 2000 mg/kg, or 3000 mg/kg. The content is largely dependenton the soil where the organic-carbon-containing material is grown, howthe material was collected, and how the material is processed. Regionsthat are land rich and more able to allow land use for growing energycrops in commercial quantities often have alkaline soils that result inorganic-carbon-containing feedstock with water-soluble salt content ofover 4000 mg/kg.

Water-soluble salts are undesirable in processes that useorganic-carbon-containing feedstock to create fuels. The salt tends toshorten the operating life of equipment through corrosion, fouling, orslagging when combusted. Some boilers have standards that limit theconcentration of salt in fuels to less than 1500 mg/kg. This is to finda balance between availability of fuel for the boilers and expense offrequently cleaning the equipment and replacing parts. If economical,less salt would be preferred. In fact, salt reduction throughbeneficiation is an enabling technology for the use of salt-ladenbiomass (e.g. hogged fuels, mesquite, and pinyon-junipers) in boilers.Salt also frequently poisons catalysts and inhibits bacteria or enzymeuse in processes used for creating beneficial fuels. While some saltconcentration is tolerated, desirably the salt levels should be as lowas economically feasible.

The water-soluble salt and various forms of water are located in variousregions in plant cells. As used herein, plant cells are composed of cellwalls that include microfibril bundles within fibrils and includeintracellular water and intracellular water-soluble salt. FIG. 1 is adiagram of a typical plant cell with an exploded view of a region of itscell wall showing the arrangement of fibrils, microfibrils, andcellulose in the cell wall. A plant cell (100) is shown with a sectionof cell wall (120) magnified to show a fibril (130). Each fibril iscomposed of microfibrils (140) that include strands of cellulose (150).The strands of cellulose pose some degree of ordering and hencecrystallinity.

Plant cells have a primary cell wall and a secondary cell wall. Thesecondary cell wall varies in thickness with type of plant and providesmost of the strength of plant material. FIG. 2 is a diagram of aperspective side view of a part of two fibrils bundled together in asecondary plant cell wall showing the fibrils containing microfibrilsand connected by strands of hemicellulose, and lignin. The section ofplant cell wall (200) is composed of many fibrils (210). Each fibril 210includes a sheath (220) surrounding an aggregate of cellulosicmicrofibrils (230). Fibrils 210 are bound together by interwoven strandsof hemicellulose (240) and lignin (250). In order to remove theintracellular water and intracellular water-soluble salt, sections ofcell wall 200 must be punctured by at least one of unbundling thefibrils from the network of strands of hemicellulose 240 and lignin 250,decrystallizing part of the strands, or depolymerizing part of thestrands.

The plant cells are separated from each other by intercellular water. Anaggregate of plant cells are grouped together in plant fibers, each witha wall of cellulose that is wet on its outside with free water alsoknown as surface moisture. The amount of water distributed within aspecific organic-carbon-containing feedstock varies with the material.As an example, water is distributed in fresh bagasse from herbaceousplants as follows: about 50 wt % intracellular water, about 30 wt %intercellular water, and about 20 wt % free water. Bagasse is thefibrous matter at remains after sugarcane or sorghum stalks are crushedto extract their juice.

FIG. 3 is diagram of a cross-sectional view of a fiber section ofbagasse showing where water and water-soluble salts reside inside andoutside plant cells. A fiber with an aggregate of plant cells (300) isshown with surface moisture (310) on the outer cellulosic wall (320).Within fiber 300 lays individual plant cells (330) separated byintercellular water (340). Within each individual plant cell 330 laysintracellular water (350) and intracellular water-soluble salt (360).

Conventional methods to beneficiate organic-carbon-containing feedstockinclude thermal processes, mechanical processes, and physiochemicalprocesses. Thermal methods include heat treatments that involvepyrolysis and torrefaction. The thermal methods do not effectivelyremove entrained salts and only serve to concentrate them. Thus thermalprocesses are not acceptable for the creation of many energy creatingproducts such as organic-carbon-containing feedstock used as a fuelsubstitute to the likes of coal and petroleum. Additionally, allconventional thermal methods are energy intensive, leading to anunfavorable overall energy balance, and thus economically limiting inthe commercial use of organic-carbon-containing feedstock as a renewablesource of energy.

The mechanical method, also called pressure extrusion or densification,can be divided into two discrete processes where water and water-solublesalts are forcibly extruded from the organic-carbon-containing material.These two processes are intercellular and intracellular extrusion. Theextrusion of intercellular water and intercellular water-soluble saltoccurs at a moderate pressure, depending upon the freshness of theorganic-carbon-containing material, particle size, initial moisturecontent, and the variety of organic-carbon-containing material.Appropriately sized particles of freshly cut herbaceousorganic-carbon-containing feedstock with moisture content between 50 wt% and 60 wt % will begin extruding intercellular moisture at pressuresas low as 1,000 psi and will continue until excessive pressure forcesthe moisture into the plant cells (essentially becoming intracellularmoisture).

As the densification proceeds, higher pressures, and hence higher energycosts, are required to try to extrude intracellular water andintracellular water-soluble salt. However, stiff cell walls provide thebiomass material with mechanical strength and are able to withstand highpressures without loss of structural integrity. In addition, theformation of impermeable felts that are more prevalent in weaker cellwalled herbaceous material has been observed during compaction ofdifferent herbaceous biomass materials above a threshold pressure. Thismethod is energy intensive. In addition, it can only remove up to 50percent of the water-soluble salts on a dry basis (the intracellularsalt remains) and is unable to reduce the remaining total water contentto below 30 wt percent.

The felts are formed when long fibers form a weave and are boundtogether by very small particles of pith. Pith is a tissue found inplants and is composed of soft, spongy parenchyma cells, which store andtransport water-soluble nutrients throughout the plant. Pith particlescan hold 50 times their own weight in water. As the compression forcesexerted during the compaction force water into the forming felts, theentrained pith particles collect moisture up to their capacity. As aresult, the moisture content of any felt can approach 90%. When feltsform during compaction, regardless of the forces applied, the overallmoisture content of the compacted biomass will be substantially higherthan it would have been otherwise had the felt not formed. The feltblocks the exit ports of the compaction device as well as segmentsperpendicular to the applied force, and the water is blocked fromexpulsion from the compaction device. The felt also blocks water passingthrough the plant fibers and plant cells resulting in some water passingback through cell wall pores into some plant cells. In addition, it canonly remove up to 50 percent of the water-soluble salts on a dry basisand is unable to reduce more than the water content to below 30 wtpercent.

The physiochemical method involves a chemical pretreatment oforganic-carbon-containing feedstock and a pressure decompression priorto compaction to substantially improve the quality of densified biomasswhile also reducing the amount of energy required during compaction toachieve the desired bulk density. Chemically, biomass comprises mostlycellulose, hemicellulose, and lignin located in the secondary cell wallof relevant plant materials. The strands of cellulose and hemicelluloseare cross-linked by lignin, forming a lignin-carbohydrate complex (LCC).The LCC produces the hydrophobic barrier to the elimination ofintracellular water. In addition to the paper pulping process thatsolublizes too much of the organic-carbon-containing material,conventional pre-treatments include acid hydrolysis, steam explosion,AFEX, alkaline wet oxidation, and ozone treatment. All of theseprocesses, if not carefully engineered, can be can be expensive on acost per product weight basis and are not designed to remove more than25% water-soluble salt on a dry weight basis.

In addition, the energy density generally obtainable from anorganic-carbon-containing material is dependent on its type, i.e.,herbaceous, soft woody, and hard woody. Also mixing types in subsequentuses such as fuel for power plants is generally undesirable because theenergy density of current processed organic-carbon-containing feedstockvaries greatly with type of plant material.

As stated above, plant material can be further subdivided in to threesub classes, herbaceous, soft woody and hard woody, each with particularwater retention mechanisms. All plant cells have a primary cell wall anda secondary cell wall. As stated earlier, the strength of the materialcomes mostly from the secondary cell wall, not the primary one. Thesecondary cell wall for even soft woody materials is thicker than forherbaceous material.

Herbaceous plants are relatively weak-walled plants, include corn, andhave a maximum height of less than about 10 to 15 feet (about 3 to 5meters (M)). While all plants contain pith particles, herbaceous plantsretain most of their moisture through a high concentration of pithparticles within the plant cells that hold water like balloons becausethese plants have relatively weak cell walls. Pressure merely deformsthe balloons and does not cause the plant to give up its water.Herbaceous plants have about 50% of their water as intracellular waterand have an energy density of unprocessed material at about 5.2 millionBTUs per ton (MMBTU/ton) or 6 Gigajoules per metric ton (GJ/MT).

Soft woody materials are more sturdy plants than herbaceous plants. Softwoody materials include pines and typically have a maximum height ofbetween 50 and 60 feet (about 15 and 18 M). Their plant cells havestiffer walls and thus need less pith particles to retain moisture. Softwoody materials have about 50% of their water as intracellular water andhave an energy density of about 13-14 MMBTU/ton (15-16 GJ/MT).

Hard woody materials are the most sturdy of plants, include oak, andtypically have a maximum height of between 60 and 90 feet (18 and 27 M).They have cellulosic plant cells with the thickest secondary cell walland thus need the least amount of pith particles to retain moisture.Hard woody materials have about 50% of their water as intracellularwater and have an energy density of about 15 MMBTU/ton (17 GJ/MT).

There is a need in the energy industry for a system and method to allowthe energy industry to use organic-carbon-containing material as acommercial alternative or adjunct fuel source. Much of the landavailable to grow renewable organic-carbon-containing material on acommercial scale also results in organic-carbon-containing material thathas a higher than desired content of water-soluble salt that typicallyis at levels of at least 4000 mg/kg. Forest products in the PacificNorthwest are often transported via intracoastal waterways, exposing thebiomass to salt from the ocean. Thus such a system and method must beable to remove sufficient levels of water-soluble salt to provide asuitable fuel substitute. As an example, boilers generally need saltcontents of less than 1500 mg/kg to avoid costly maintenance related tohigh salt in the fuel. In addition, the energy and resulting cost toremove sufficient water to achieve an acceptable energy density must below enough to make the organic-carbon-containing material feedstock asuitable alternative in processes to make coal or hydrocarbon fuelsubstitutes.

There is also a need for a process that can handle the various types ofplants and arrive at processed organic-carbon-containing feedstock withsimilar energy densities.

The invention disclosed does allow the energy industry to use processedorganic-carbon-containing material as a commercial alternative fuelsource. Some embodiments of the invention remove almost all of thechemical contamination, man-made or natural, and lower the total watercontent to levels in the range of 5 wt % to 15 wt %. This allows theindustries, such as the electric utility industry to blend theorganic-carbon-containing feedstock on a ratio of up to 50 wt %processed organic-carbon-containing feedstock to 50 wt % coal with asubstantial reduction in the amount of water-soluble salt and enjoy thesame MMBTU/ton (GJ/MT) efficiency as coal at coal competitive prices.Literature has described organic-carbon-containing feedstock to coalratios of up to 30%. A recent patent application publication, EP2580307A2, has described a ratio of up to 50% by mechanical compaction underheat, but there was no explicit reduction in water-soluble salt contentin the organic-carbon-containing feedstock. The invention disclosedherein explicitly comprises substantial water-soluble salt reductionthrough a reaction chamber with conditions tailored to each specificunprocessed organic-carbon-containing feedstock used. As discussedbelow, additional purposed rinse subsections and subsequent pressingalgorithms in the compaction section of the Reaction Chamber may bebeneficial to process organic-carbon-containing feedstock that has aparticularly high content of water-soluble salt so that it may be usedin a blend with coal that otherwise would be unavailable for burning ina coal boiler. This also includes, for example, hog fuel, mesquite, andEastern red cedar.

In addition, the invention disclosed does permit different types oforganic-carbon-containing feedstock to be processed, each at tailoredconditions, to result in processed outputs having preselected energydensities. In some embodiments of the invention, more than one type offeedstock with different energy densities that range from 5.2 to 14MMBTU/ton (6 to 16 GJ/MT) may be fed into the reaction chamber in seriesor through different reaction chambers in parallel. Because each type oforganic-carbon-containing feedstock is processed under preselectedtailored conditions, the resulting processed organic-carbon-containingfeedstock for some embodiments of the system of the invention can have asubstantially similar energy density. In some embodiments, the energydensity is about 17 MMBTU/ton (20 GJ/MT). In others it is about 18, 19,or 20 MMBTU/ton (21, 22, or 23 GJ/MT). This offers a tremendousadvantage for down-stream processes to be able to work with processedorganic-carbon-containing feedstock having similar energy densityregardless of the type used as well as substantially reducedwater-soluble content.

The process of the invention uses a beneficiation sub-system to createthe processed organic-carbon-containing feedstock that is a cleaneconomical material to be used for creating a satisfactory coalsubstitute solid fuel from renewable biomass and a pelletizing subsystemfor converting the processed organic-carbon-containing feedstock intothe solid processed biomass pellets of the invention. The firstsubsystem will now be discussed.

Beneficiation Sub-System

The beneficiation sub-system is used to make processedorganic-carbon-containing feedstock comprises at least three elements, atransmission device, at least one reaction chamber, and a collectiondevice. As used in this document, the beneficiation sub-system refers tothe system that is used to convert unprocessed organic-carbon-containingfeedstock into processed organic-carbon-containing feedstock.

The first element, the transmission device, is configured to convey intoa reaction chamber unprocessed organic-carbon-containing feedstockcomprising free water, intercellular water, intracellular water,intracellular water-soluble salt, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, and cellulosicmicrofibrils within fibrils. The transmission device may be any that issuitable to convey solid unprocessed organic-carbon-containing feedstockinto the reaction chamber to obtain a consistent residence time of thefeedstock in the reaction chamber. The transmission devices include suchdevices at augers that are well known in the chemical industry.

Particle size of the unprocessed organic-carbon-containing feedstockshould be sufficiently small to permit a satisfactorily energy balanceas the unprocessed organic-carbon-containing feedstock is passed throughthe system to create processed organic-carbon-containing feedstock. Insome embodiments, the unprocessed organic-carbon-containing feedstockarrives at some nominal size. Herbaceous material such as, for example,energy crops and agricultural waste, should have a particle size wherethe longest dimension is less than 1 inch (2.5 cm). Preferably, mostwood and wood waste that is freshly cut should have a longest length ofless than 0.5 inches (1.3 cm). Preferably, old wood waste, especiallyresinous types of wood such as, for example pine, has a particle sizewith a longest dimension of less than 0.25 inches (about 0.6 cm) toobtain the optimum economic outcome, where throughput andenergy/chemical consumption are weighed together.

Some embodiments of the system may also include a mastication chamberbefore the reaction chamber. This mastication chamber is configured toreduce particle size of the organic-carbon-containing feedstock to lessthan 1 inch (2.5 cm) as the longest dimension. This allows theorganic-carbon-containing feedstock to arrive with particle sized havinga longest dimension larger than 1 inch (2.5 cm). In some embodiments,the longest dimension is less than 0.75 inches (1.9 cm), and in someless than 0.5 inches (1.3 cm).

Some embodiments of the system may also include a pretreatment chamberto remove contaminants that hinder creation of the passageways forintracellular water and water-soluble salts to pass from thecellulosic-fibril bundles. The chamber is configured to use for eachorganic-carbon-containing feedstock a particular set of conditionsincluding time duration, temperature profile, and chemical content ofpretreatment solution to at least initiate the dissolution ofcontaminates. The contaminants include resins, rosins, glue, andcreosote. The solid slurry, including any incipient felts, may becollected for use as binders in the processed organic-carbon-containingfeedstock that is the primary end product. Separate oils may becollected as a stand-alone product such as, for example, cedar oil.

The second element, the reaction chamber, includes at least one entrancepassageway, at least one exit passageway, and at least three sections, awet fibril disruption section, a vapor explosion section, and acompaction section. The first section, the wet fibril disruptionsection, is configured to break loose at least some of the lignin andhemicellulose between the cellulosic microfibrils in the fibril bundleto make at least some regions of cell wall more penetrable. This isaccomplished by at least one of several means. Theorganic-carbon-containing feedstock is mixed with appropriate chemicalsto permeate the plant fibrils and disrupt the lignin, hemicellulose, andLCC barriers. Additionally, the chemical treatment may also unbundle aportion of the cellulose fibrils and/or microfibrils, de-crystallizingand/or de-polymerizing it. Preferably, the chemicals are tailored forthe specific organic-carbon-containing feedstock. In some embodiments,the chemical treatment comprises an aqueous solution containing amiscible volatile gas. The miscible gas may include one or more ofammonia, bicarbonate/carbonate, or oxygen. Some embodiments may includeaqueous solutions of methanol, ammonium carbonate, or carbonic acid. Theuse of methanol, for example, may be desirable fororganic-carbon-containing feedstock having a higher woody content todissolve resins contained in the woody organic-carbon-containingfeedstock to allow beneficiation chemicals better contact with thefibrils. After a predetermined residence time of mixing, theorganic-carbon-containing feedstock may be steam driven, or conveyer byanother means such as a piston, into the next section of the reactionchamber. In some embodiments, process conditions should be chosen to notdissolve more than 25 wt % of the lignin or hemicellulose as these areimportant contributors to the energy density of the processedorganic-carbon-containing feedstock. Some embodiments of the system,depending on the specific organic-carbon-containing feedstock used, mayhave temperatures of at least 135° C., at least 165° C., or at least180° C.; pressures of at least 260 psig, at least 280 psig, at least 375psig, or at least 640 psig; and residence times of at least 15 minutes(min), 20 min, or 30 min.

In some embodiments, micro-particles and lignin-rich fragments suspendedin the effluent is withdrawn from the reactive chamber for subsequentuse. The micro particles and lignin is cleansed of water-soluble saltsand other impurities as needed. The resulting slurry, often white, actsas a high energy biomass binder that is then mixed with the processedorganic-carbon-containing feedstock before the pelletizing step. Thisreduces the need for heat during pelletizing.

The second section, the vapor explosion section, is in communicationwith the wet fibril disruption section. It at least is configured tovolatilize plant fibril permeable fluid through rapid decompression topenetrate the more susceptible regions of the cell wall so as to createa porous organic-carbon-containing feedstock with cellulosic passagewaysfor intracellular water and water-soluble salts to pass from thecellulosic-fibril bundles. The organic-carbon-containing feedstock isisolated, heated, pressurized with a volatile fluid comprising steam.The applied volatile chemicals and steam penetrate into the plantfibrils within the vapor explosion section due to the high temperatureand pressure. After a predetermined residence time dictated by thespecific organic-carbon-containing feedstock used, pressure is releasedrapidly from the reaction chamber by opening a fast-opening valve intoan expansion chamber that may be designed to retain the gases, separatethem, and reuse at least some of them in the process for increasedenergy/chemical efficiency. Some embodiments may have no expansionchamber where retention of gasses is not desired. Some embodiments ofthe system, depending on the specific organic-carbon-containingfeedstock used, may have a specific pressure drop in psig of at least230, at least 250, at least 345, or at least 600; and explosivedurations of less than 500 milliseconds (ms), less than 300 ms, lessthan 200 ms, less than 100 ms, or less than 50 ms.

Some embodiments may include gas inlets into the wet fibril disruptionsection of the reaction chamber to deliver compressed air or othercompressed gas such as, for example, oxygen. After delivery to thedesired pressure, the inlet port would be closed and the heating for thereaction would proceed. Note that this could allow for at least one ofthree things: First, an increase in total pressure would make subsequentexplosion more powerful. Second, an increase in oxygen content wouldincrease the oxidation potential of the processedorganic-carbon-containing feedstock where desirable. Third, a provisionwould be provided for mixing of organic-carbon-containing feedstock,water, and potentially other chemicals such as, for example, organicsolvents, through bubbling action of gas through a perforated pipe atbottom of reaction chamber.

The net effect on the organic-carbon-containing feedstock of passingthrough the wet fibril disruption section and the vapor explosionsection is the disruption of fibril cell walls both physically throughpressure bursts and chemically through selective and minimal fibrilcellulosic delinking, cellulose depolymerization and/or cellulosedecrystallization. Chemical effects, such as hydrolysis of thecellulose, lignin, and hemicellulose also can occur. The resultingorganic-carbon-containing feedstock particles exhibit an increase in thesize and number of micropores in their fibrils and cell walls, and thusan increased surface area. The now porous organic-carbon-containingfeedstock is expelled from the vapor explosion section into the nextsection.

The third section, the compaction section is in communication with thevapor explosion section. The compression section at least is configuredto compress the porous organic-carbon-containing feedstock betweenpressure plates configured to minimize formation of felt that wouldclose the reaction chamber exit passageway made to permit escape ofintracellular and intercellular water, and intracellular andintercellular soluble salts. In this section, the principle processconditions for each organic-carbon-containing feedstock is the presenceor absence of a raised pattern on the pressure plate, the starting watercontent, the processed water content, and final water content. Thecompaction section of the system of the invention requires a raisedpatterned surface on the pressure plates for feedstock comprisingherbaceous plant material feedstock. However, the section may or may notrequire the raised pattern surface for processing soft woody or hardwoody plant material feedstock depending on the specific material usedand its freshness from harvest. Some embodiments of the system,depending on the specific organic-carbon-containing feedstock used, mayhave a starting water contents ranging from 70 to 80 wt %, from 45 to 55wt % or from 40 to 50 wt %; and processed water content of from 4 to 15wt % depending on actual targets desired.

The third element, the collection device, is in communication with thereaction chamber. The collection chamber at least is configured toseparate non-fuel components from fuel components and to create aprocessed organic-carbon-containing feedstock. This feedstock has awater content of less than 20 wt % and a water-soluble salt content thatis decreased by at least 60% on a dry basis. Some embodiments have thewater content less than 20 wt % after allowing for surface moisture toair dry. Some embodiments have a processed organic-carbon-containingfeedstock that has a water content of less than 15 wt %. Otherembodiments have processed organic-carbon-containing feedstock that hasa water content of less than 12 wt %, less than 10 wt %, less than 8 wt%, or less than 5 wt %. Some embodiments have a water-soluble saltcontent that is decreased by at least 65% on a dry basis. Otherembodiments have a water-soluble salt content that is decreased by atleast 70% on a dry basis, 75% on a dry basis, at least 80% on a drybasis, at least 85% on a dry basis, at least 90% on a dry basis, or atleast 95% on a dry basis.

Some embodiments of the system may further include at least one rinsingsubsection. This subsection is configured to flush at least some of thewater-soluble salt from the porous organic-carbon-containing feedstockbefore it is passed to the compaction section. In some embodiments wherethe salt content is particularly high, such as brine-soaked hog fuel(wood chips, shavings, or residue from sawmills or grinding machine usedto create it and also known as “hammer hogs”), the system is configuredto have more than one rinsing subsection followed by another compactionsection. The separated water, complete with dissolved water solublesalts, may be collected and treated for release into the surroundingenvironment or even reused in the field that is used to grow therenewable organic-carbon-containing feedstock. The salts in this waterare likely to include constituents purposefully added to the crops suchas fertilizer and pesticides.

The beneficiation sub-system of the invention can better be understoodthrough depiction of several figures. FIG. 4 is a diagram of a side viewof an embodiment of a reaction chamber in communication with anexpansion chamber to retain gasses emitted from the decompressedcarbon-containing feedstock. A reaction chamber (400) is shown with awet fibril disruption section (410). Solvent (412) and unprocessedorganic-carbon-containing feedstock (414) that has been chipped to lessthan 0.5 inches (1.3 cm) are fed into wet fibril disruption section 410through valves (416) and (418), respectively to become prepared for thenext section. The pretreated organic-carbon-containing feedstock is thenpassed to a vapor explosion section (420) through a valve (422). Valvesare used between chambers and to input materials to allow for attainmentof specified targeted conditions in each chamber. Volatile expansionfluid, such as water, or water based volatile mixtures, are fed in tovapor expansion chamber 420 through a valve (424). The gas released fromthe porous organic-carbon-containing feedstock created duringdecompression is fed through a fast release valve (428) into anexpansion chamber (not shown) to retain the gas for possible reuse. Thecompaction section (430) received the porous organic-carbon-containingfeedstock through a valve (432) where the water and water-soluble saltare substantially removed from porous organic-carbon-containingfeedstock and it is now processed organic-carbon-containing feedstock.

As stated above, the pressure plates in the compaction section areconfigured to minimize felt formation. Felt is an agglomeration ofinterwoven fibers that interweave to form an impermeable barrier thatstops water and water-soluble salts entrained in that water from passingthrough the exit ports of the compaction section. Additionally, any pithparticles that survived the beneficiation process in the first twosections of reaction chamber can be entrained in the felt to absorbwater, thereby preventing expulsion of the water during pressing.Therefore, felt formation traps a significant fraction of the water andsalts from being extruded from the interior of biomass being compressed.FIGS. 5A, 5B, and 5C show embodiments of pressure plates and how theywork to minimize felt formation so that water and water-soluble saltsare able to flow freely from the compaction section. FIG. 5A is adiagram of the front views of various embodiments of pressure plates.Shown is the surface of the pressure plate that is pressed against thedownstream flow of porous organic-carbon-containing feedstock. FIG. 5Bis a perspective view of a close-up of one embodiment of a pressureplate shown in FIG. 5A. FIG. 5C is a diagram showing the cross-sectionalview down the center of a pressure plate with force vectors and feltexposed to the force vectors. The upstream beneficiation process in thefirst two sections of the reaction chamber has severely weakened thefibers in the biomass, thereby also contributing to the minimization offelt formation.

Some embodiments achieve the processed organic-carbon-containingfeedstock water content and water-soluble salt reduction overunprocessed organic-carbon-containing feedstock with a cost that is lessthan 60% that of the cost per weight of processedorganic-carbon-containing feedstock from known mechanical, knownphysiochemical, or known thermal processes. In these embodiments, thereaction chamber is configured to operate at conditions tailored foreach unprocessed organic-carbon-containing feedstock and the system isfurther engineered to re-capture and reuse heat to minimize the energyconsumed to lead to a particular set of processedorganic-carbon-containing feedstock properties. The reaction chambersections are further configured as follows. The wet fibril disruptionsection is further configured to use fibril disruption conditionstailored for each organic-carbon-containing feedstock and that compriseat least a solvent medium, time duration, temperature profile, andpressure profile for each organic-carbon-containing feedstock. Thesecond section, the vapor explosion section, is configured to useexplosion conditions tailored for each organic-carbon-containingfeedstock and that comprise at least pressure drop, temperature profile,and explosion duration to form volatile plant fibril permeable fluidexplosions within the plant cells. The third section, the compactionsection, is configured to use compaction conditions tailored for eachorganic-carbon-containing feedstock and pressure, pressure plateconfiguration, residence time, and pressure versus time profile.

The importance of tailoring process conditions to eachorganic-carbon-containing feedstock is illustrated by the followingdiscussion on the viscoelastic/viscoplastic properties of plant fibrils.Besides the differences among plants in their cell wall configuration,depending on whether they are herbaceous, soft woody or hard woody,plants demonstrate to a varying degree of some interesting physicalproperties. Organic-carbon-containing material demonstrates both elasticand plastic properties, with a degree that depends on both the specificvariety of plant and its condition such as, for example, whether it isfresh or old. The physics that governs the elastic/plastic relationshipof viscoelastic/viscoplastic materials is quite complex. Unlike purelyelastic substances, a viscoelastic substance has an elastic componentand a viscous component. Similarly, a viscoplastic material has aplastic component and a viscous component. The speed of pressing aviscoelastic substance gives the substance a strain rate dependence onthe time until the material's elastic limit is reached. Once the elasticlimit is exceeded, the fibrils in the material begin to suffer plastic,i.e., permanent, deformation. FIG. 6A is a graphical illustration of thetypical stress-strain curve for lignocellulosic fibril. Since viscosity,a critical aspect of both viscoelasticity and viscoplasticity, is theresistance to thermally activated deformation, a viscous material willlose energy throughout a compaction cycle. Plastic deformation alsoresults in lost energy as observed by the fibril's failure to restoreitself to its original shape. Importantly,viscoelasticity/viscoplasticity results in a molecular rearrangement.When a stress is applied to a viscoelastic material, such as aparticular organic-carbon-containing feedstock, some of its constituentfibrils and entrained water molecules change position and, while doingso, lose energy in the form of heat because of friction. It is importantto stress that the energy that the material loses to its environment isenergy that is received from the compactor and thus energy that isexpended by the process. When additional stress is applied beyond thematerial's elastic limit, the fibrils themselves change shape and notjust position. A “visco”-substance will, by definition, lose energy toits environment in the form of heat.

An example of how the compaction cycle is optimized for oneorganic-carbon-containing feedstock to minimize energy consumption toachieve targeted product values follows. Through experimentation, abalance is made between energy consumed and energy density achieved.FIG. 6B is a graphical illustration of pressure and energy required todecrease the water content and increase the bulk density of typicalorganic-carbon-containing feedstock. Bulk density is related to watercontent with higher bulk density equaling lower water content. Theorganic-carbon-containing feedstock compaction process will strike anoptimum balance between cycle time affecting productivity, net moistureextrusion together with associated water-soluble salts and minerals,permanent bulk density improvement net of the rebound effect due toviscoelastic/viscoplastic properties of the feedstock, and energyconsumption.

FIG. 6C is an experimentally derived graphical illustration of theenergy demand multiplier needed to achieve a bulk density multiplier.The compaction cycle can be further optimized for each variety andcondition of organic-carbon-containing feedstock to achieve the desiredresults at lesser pressures, i.e., energy consumption, by incorporatingbrief pauses into the cycle. FIG. 6D is a graphical illustration of anexample of a pressure cycle for decreasing water content in anorganic-carbon-containing feedstock with an embodiment of the inventiontailored to a specific organic-carbon-containing feedstock.

In a similar manner, energy consumption can be optimized during the wetfibril disruption and the vapor explosion parts of the system. Chemicalpretreatment prior to compaction will further improve the quality of theproduct and also reduce the net energy consumption. For comparisonpurposes, the pressure applied to achieve a bulk density multiplier of“10” in FIG. 6C was on the order of 10,000 psi, requiring uneconomicallyhigh cost of capital equipment and unsatisfactorily high energy costs todecompress the organic-carbon-containing feedstock.

FIG. 7 is a table illustrating the estimated energy consumption neededto remove at least 75 wt % water-soluble salts fromorganic-carbon-containing feedstock and reduce water content from 50 wt% to 12 wt % with embodiments of the invention compared with knownprocesses. Waste wood with a starting water content of 50 wt % was usedin the estimate to illustrate a side-by-side comparison of threeembodiments of the invention with known mechanical, physiochemical, andthermal processes. The embodiments of the system selected use a fibrilswelling fluid comprising water, water with methanol, water with carbondioxide bubbled into it produces carbonic acid H₂CO₃. As seen in thetable, and discussed above, known mechanical processes are unable toreduce the water content to 12 wt %, known physiochemical processes areunable to reduce water-soluble salt content by over 25 wt %, and knownthermal processes are unable to remove any water-soluble salt. The totalenergy requirement per ton for the three embodiments of the invention,that using methanol and water, carbon dioxide and water, and just wateris 0.28 MMBTU/ton (0.33 GJ/MT), 0.31 MMBTU/ton (0.35 GJ/6T), and 0.42MMBTU/ton (0.49 GJ/MT), respectively. This is compared to 0.41 MMBTU/ton(0.48 GJ/MT), 0.90 MMBTU/ton (1.05 GJ/MT), and 0.78 MMBTU/ton (0.93GJ/MT) for known mechanical, known physiochemical, and known thermalprocesses, respectively. Thus, the estimated energy requirements toremove water down to a content of less than 20 wt % and water-solublesalt by 75 wt % on a dry basis for embodiments of the system inventionto less than 60% that of known physiochemical and known thermalprocesses that are able to remove that much water and water-solublesalt. In addition, the system invention is able to remove far morewater-soluble salt than is possible with known physiochemical and knownthermal processes that are able to remove that much water.

Multiple reaction chambers may be used in parallel to simulate acontinuous process. FIG. 8 is a diagram of a side view of an embodimentof a beneficiation sub-system having four reaction chambers in parallel,a pretreatment chamber, and a vapor condensation chamber. A system (800)includes an input section (802) that delivers organic-carbon-containingfeedstock to system 800. Feedstock passes through a mastication chamber(804) prior to entry into an organic-carbon-containing feedstock hopper((806) from where is passes on to a pretreatment chamber (810).Contaminants are removed through a liquid effluent line (812) to aseparation device (814) such as a centrifuge and having an exit stream(815) for contaminants, a liquid discharge line (816) that moves liquidto a filter media tank (818) and beyond for reuse, and a solid dischargeline (820) that places solids back into the porousorganic-carbon-containing feedstock. Liquid from the filter medial tank818 is passed to a remix tank (822) and then to a heat exchanger (824)or to a second remix tank (830) and to pretreatment chamber 810. Theorganic-carbon-containing feedstock passes onto one of four reactionchambers (840) comprising three sections. The first section of eachreaction chamber, a wet fibril disruption section (842), is followed bythe second section, a vapor explosion section (844), and a rinsingsubsection (846). A high pressure steam boiler (848) is fed by a makeupwater line (850) and the heat source (not shown) is additionally heatedwith fuel from a combustion air line (852). The main steam line (854)supplies steam to pretreatment chamber 810 and through high pressuresteam lines (856) to reaction chambers 840. A vapor expansion chamber(860) containing a vapor condensation loop is attached to each vaporexplosion sections with vapor explosion manifolds (862) to condense thegas. A volatile organic components and solvent vapor line (864) passesthe vapor back to a combustion air line (852) and the vapors in vaporexpansion chamber 860 are passes through a heat exchanger (870) tocapture heat for reuse in reaction chamber 840. The now porousorganic-carbon-containing feedstock now passes through the third sectionof reaction chamber 840, a compaction section (880). Liquid fluid passesthrough the liquid fluid exit passageway (884) back through fluidseparation device (814) and solid processed organic-carbon-containingfeedstock exits at (886).

Pelletizing Sub-System

The pelletizing sub-system is used to convert the processedorganic-carbon-containing feedstock from the beneficiation sub-systeminto the pellets suitable for use in electricity-making power plants.The pelletizing sub-system comprises a compression chamber and acollection chamber. The a compression chamber is configured to separatethe processed organic-carbon-containing feedstock into discrete units ofmass having a longest length of at least 0.16 inch (4.0 cm) and adensity of at least 37.5 pounds per cubic foot (0.60 grams per cubiccentimeter) to form processed biomass pellets. In some embodiments thecompression is done under heat. In other embodiments, the slurry ofmicro particles and lignin from the reactor of the beneficiationsub-system, discussed above, is mixed with the processedorganic-carbon-containing feedstock before compression. This results inthe need for little if any heat or high energy biomass binder to formthe processed biomass pellets. The collection chamber is configured togather an aggregate of processed biomass pellets.

In some embodiments, the pelletizing sub-system further comprises aheating chamber configured to apply sufficient heat to the processedorganic-carbon-containing feedstock to reduce its water content to lessthan 10% by weight and form pellets. In some embodiments, thecompression chamber and the heating chamber are the same chamber.

In some embodiments, the vapor explosion section of the beneficiationsub-system further comprises a wash element that is configured to removeand clean micro particles of unprocessed organic-carbon-containingfeedstock, lignin fragments, and hemicellulosic fragments from the vaporexplosion section into a fine, sticky mass of biomass with high lignincontent. In this embodiment, the blending chamber of the blendingsubsection, discussed below, is further configured to receive the fine,sticky mass of biomass to permit at least one of lower temperatures orless if any additional high energy biomass binder content in acompaction chamber formation during formation of blended compactaggregates.

FIG. 9 is a diagram of a process to make pellets from unprocessedorganic-carbon-containing feedstock with the addition of micro particleand lignin slurry that is optional. In this embodiment, the unprocessedorganic-carbon-containing feedstock, untreated biomass input, is sized(910), then passed through beneficiation reaction chamber where thefibers are disrupted (920), the salt is solubilized and the feedstock isthen washed (930). During this step, the effluent containing microparticles and lignin is removed (940), washed and introduced to theprocessed organic-carbon-containing feedstock in a remixing step (960)after it has gone through a dewatering and desolvating step (950). Themixture is then pelletized (970) and collected (980). The use of thewashed effluent stream serves to reduce the need for heat to form thepellets although heat still may be advantageous to remove additionalwater.

Beneficiation Sub-System Process

The beneficiation process step comprises the step of passing unprocessedorganic-carbon-containing feedstock through a beneficiation sub-systemprocess to result in processed organic-carbon-containing feedstockhaving a water content of less than 20 wt % and a salt content that isreduced by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the unprocessedorganic-carbon-containing feedstock. There are two aspects of thebeneficiation sub-system process. The first focuses on the properties ofthe processed organic-carbon-containing feedstock and the second focuseson the energy efficiency of the process of the invention over that ofcurrently known processes for converting unprocessedorganic-carbon-containing feedstock into processedorganic-carbon-containing feedstock suitable for use with downstreamfuel producing systems. Both use the beneficiation sub-system disclosedabove.

First Aspect

The first aspect of the beneficiation process step of the inventioncomprises four steps. The first step is inputting into a reactionchamber unprocessed organic-carbon-containing feedstock comprising freewater, intercellular water, intracellular water, intracellularwater-soluble salts, and at least some plant cells comprising cell wallsthat include lignin, hemicellulose, and microfibrils within fibrils.Some embodiments have unprocessed organic-carbon-containing feedstockthat comprises water-soluble salts having a content of at least 4000mg/kg on a dry basis.

The second step is exposing the feedstock to hot solvent under pressurefor a time at conditions specific to the feedstock to make at least someregions of the cell walls comprising crystallized cellulosic fibrils,lignin, and hemicellulose more able to be penetrable by water-solublesalts without dissolving more than 25 percent of the lignin andhemicellulose. As mentioned above, this is accomplished by one or moreof unbundling regions of at least some fibrils, depolymerizing at leastsome strands of lignin and/or hemicellulose, or detaching them from thecellulose fibrils, thereby disrupting their interweaving of the fibrils.In addition, the cellulose fibrils and microfibrils can be partiallydepolymerized and/or decrystallized. In some embodiments, microparticles and lignin that is removed in an effluent stream is furthercleansed of water-soluble salts and other impurities as needed before itis subsequently mixed with the processed organic-carbon-containingfeedstock before pelletizing.

The third step is rapidly removing the elevated pressure so as topenetrate the more penetrable regions with intracellular escaping gasesto create porous feedstock with open pores in at least some plant cellwalls. In some embodiments the pressure is removed to about atmosphericpressure in less than 500 milliseconds (ms), less than 300 ms, less than200 ms, less than 100 ms, or less than 50 ms.

The fourth step is pressing the porous feedstock with conditions thatinclude an adjustable compaction pressure versus time profile andcompaction time duration, and between pressure plates configured toprevent felt from forming and blocking escape from the reaction chamberof intracellular and intercellular water and intracellular water-solublesalts, and to create processed organic-carbon-containing feedstock thathas a water content of less than 20 wt % and a water-soluble saltcontent that is decreased by at least 60% on a dry basis that of theunprocessed organic-carbon-containing feedstock. In some embodiments,the water content is measured after subsequent air-drying to removeremaining surface water. In some embodiments, the pressure plate has apattern that is adapted to particular organic-carbon-containingfeedstock based on its predilection to form felts and pith content asdiscussed above. In some embodiments, the pressure amount and pressureplate configuration is chosen to meet targeted processedorganic-carbon-containing feedstock goals for particular unprocessedorganic-carbon-containing feedstock. In some embodiments, the pressureis applied in steps of increasing pressure, with time increments ofvarious lengths depending on biomass input to allow the fibers to relaxand more water-soluble salt to be squeezed out in a more energyefficient manner. In some embodiments, clean water is reintroduced intothe biomass as a rinse and to solublize the water-soluble slats beforethe fourth step begins.

The process may further comprise a fifth step, prewashing theunprocessed organic-carbon-containing feedstock before it enters thereaction chamber with a particular set of conditions for eachorganic-carbon-containing feedstock that includes time duration,temperature profile, and chemical content of pretreatment solution to atleast initiate the dissolution of contaminates that hinder creation ofthe cell wall passageways for intracellular water and intracellularwater-soluble salts to pass outward from the interior of the plantcells.

The process may further comprise a sixth step, masticating. Theunprocessed organic-carbon-containing feedstock is masticated intoparticles having a longest dimension of less than 1 inch (2.5centimeters) before it enters the reaction chamber.

The process may further comprise a seventh step, separating out thecontaminants. This step involves the separating out of at least oils,waxes, and volatile organic compounds from the porous feedstock withsolvents less polar than water.

As with the system aspect, the unprocessed organic-carbon-containingfeedstock may comprise at least two from a group consisting of anherbaceous plant material, a soft woody plant material, and a hard woodyplant material that are processed in series or in separate parallelreaction chambers. In addition, in some embodiments, the energy densityof each plant material in the processed organic-carbon-containingfeedstock may be substantially the same. In some embodiments, theorganic-carbon-containing feedstock comprises at least two from thegroup consisting of an herbaceous plant material, a soft woody plantmaterial, and a hard woody plant material, and wherein the energydensity of each plant material in the processedorganic-carbon-containing feedstock is at least 17 MMBTU/ton (20 GJ/MT).

FIG. 10 is a block diagram of a process for making processedorganic-carbon-containing feedstock with less than 60 percentwater-soluble salt on a dry basis over that of its unprocessed form andwith less than 20 wt % water. Step 1710 involves inputting unprocessedorganic-carbon-containing feedstock that has at least some plant cellsthat include intracellular water-soluble salt and cell walls comprisinglignin into a reaction chamber. Step 1720 involves exposing thefeedstock to hot solvent under pressure for a time to make some regionsof the cell walls comprising crystallized cellulosic fibrils, lignin,and hemicellulose more able to be penetrable by water-soluble saltswithout dissolving more than 25 percent of the lignin andhemicelluloses. Step 1730 involves removing the pressure so as topenetrate at least some of the cell walls so as to create porousfeedstock with open pores in its plant cell walls. Step 1740 involvespressing the porous feedstock with a plate configured to prevent feltfrom blocking escape of intracellular water and intracellularwater-soluble salts from the reaction chamber so as to create processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt % and a water-soluble salt content that is decreased by atleast 60 wt % on a dry basis for the processed organic-carbon-containingfeedstock from that of unprocessed organic-carbon-containing feedstock.

Second Aspect

The second aspect is similar to the first except steps have anefficiency feature and the resulting processed organic-carbon-containingfeedstock has a cost feature. The second aspect also comprises foursteps. The first step is inputting into a reaction chamberorganic-carbon-containing feedstock comprising free water, intercellularwater, intracellular water, intracellular water-salts, and at least someplant cells comprising lignin, hemicellulose, and fibrils within fibrilbundles. Each step emphasizes more specific conditions aimed at energyand material conservation. The second step is exposing the feedstock tohot solvent under pressure for a time at conditions specific to thefeedstock to swell and unbundle the cellular chambers comprisingpartially crystallized cellulosic fibril bundles, lignin, hemicellulose,and water-soluble salts without dissolving more than 25 percent of thelignin and to decrystallize at least some of the cellulosic bundles. Thethird step is removing the pressure to create porous feedstock with openpores in its cellulosic chambers. After possibly mixing with fresh waterto rinse the material and solublize the water-soluble salts, the fourthstep is pressing the porous feedstock with an adjustable compactionpressure versus time profile and compaction duration between pressureplates configured to prevent felt from forming and blocking escape fromthe reaction chamber of intracellular and intercellular water andintracellular water-soluble salts, and to create a processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt %, a water-soluble salt content that is decreased by at least60 wt % on a dry basis, and a cost per weight of removing the water andthe water-soluble salt is reduced to less than 60% of the cost perweight of similar water removal from known mechanical, knownphysiochemical, or known thermal processes.

FIG. 11 is a block diagram of a process for making processedorganic-carbon-containing feedstock with less than 50 wt % water-solublesalt of a dry basis than that of unprocessed organic-carbon-containingfeedstock and less than 20 wt % water, and at a cost per weight of lessthan 60% that of similar water removal from known mechanical, knownphysiochemical, or known thermal processes that can remove similaramounts of water and water-soluble salt. Step 1810 involves inputtingunprocessed organic-carbon-containing feedstock that has at least plantcells comprising intracellular water-soluble salts and plant cell wallsthat include lignin into a reaction chamber. Step 1820 involves exposingthe feedstock to hot solvent under pressure for a time to make someregions of the cell walls comprising of crystallized cellulosic fibrils,lignin, and hemicellulose more able to be penetrable by water-solublesalts without dissolving more than 25 percent of the lignin andhemicelluloses. Step 1830 involves removing the pressure so as topenetrate at least some of the cell walls to create porous feedstockwith open pores in its plant cell walls. Step 1840 involves pressing theporous feedstock with a plate configured to prevent felt from blockingescape of intracellular water and intracellular water-soluble salts fromthe reaction chamber so as to create processed organic-carbon-containingfeedstock that has a water content of less than 20 wt %, a water-solublesalt content that is decreased by at least 60 wt % on a dry basis overthat of unprocessed organic-carbon-containing feedstock, and a cost perweight of removing the water and water-soluble salt that is reduced toless than 60% of the cost per weight of similar water removal from knownmechanical, physiochemical, or thermal processes.

Energy efficiencies are achieved in part by tailoring process conditionsto specific organic-carbon-containing feedstock as discussed above. Someembodiments use systems engineered to re-capture and reuse heat tofurther reduce the cost per ton of the processedorganic-carbon-containing feedstock. Some embodiments remove surface orfree water left from the processing of the organic-carbon-containingfeedstock with air drying, a process that takes time but has noadditional energy cost. FIG. 12 is a table that shows some processvariations used for three types of organic-carbon-containing feedstocktogether with the resulting water content and water-soluble salt contentachieved. It is understood that variations in process conditions andprocessing steps may be used to raise or lower the values achieved inwater content and water-soluble salt content and energy cost to achievetargeted product values. Some embodiments have achieved water contentsas low as less than 5 wt % and water-soluble salt contents reduced by asmuch as over 95 wt % on a dry basis from its unprocessed feedstock form.

Pelletizing Sub-System Process

The pelletizing sub-system process step comprises two steps. The firststep is compressing the processed organic-carbon-containing feedstock toseparate it into pellets with discrete units of mass having a longestlength of at least 0.16 inch (4.0 cm), a diameter of less than 0.25 inch(6 mm), and a density of at least 37.5 pounds per cubic foot (0.60 gramsper cubic centimeter). The second step is collecting the aggregate ofpellets. In some embodiments the compression is done under heat to atleast assist the formation of aggregates or reduce the content of waterto less than 10% by weight. In some embodiments, the steps ofcompression and heating are done at the same time. In some embodiments,the beneficiation sub-system process further comprises removing andcleaning of micro particles of unprocessed organic-carbon-containingfeedstock, lignin fragments, and hemicellulosic fragments from the vaporexplosion section into a fine, sticky mass of biomass with high lignincontent in the removing the pressure step, and the blending sub-systemfurther comprises adding the fine, sticky mass of biomass to the blendedpowder to permit lower temperatures in the compressing step duringformation of blended compact aggregates.

Various modifications and additions can be made to the preferredembodiments discussed hereinabove without departing from the scope ofthe present invention. Accordingly, the scope of the present inventionshould not be limited by the particular embodiments described above, butshould be defined only by the claims set forth below and equivalentsthereof.

What is claimed is:
 1. A composition, comprising: a processed biomasspellet composition that comprises a processed organic-carbon-containingfeedstock with characteristics that include an energy density of atleast 17 MMBTU/ton (20 GJ/MT), a water content of less than 20 wt %, anda water-soluble intracellular salt content that is decreased more than60 wt % on a dry basis for the processed organic-carbon-containingfeedstock from that of unprocessed organic-carbon-containing feedstock,and the processed biomass pellet is made from unprocessedorganic-carbon-containing feedstock that is converted into the processedorganic-carbon-containing feedstock with a beneficiation sub-system, andinto the processed biomass pellet with a pelletizing sub-system that ismade with 40% less energy than expended to make an unprocessed biomasspellet.
 2. The composition of claim 1 wherein the beneficiationsub-system, comprises: a. a transmission device configured to conveyinto a reaction chamber unprocessed organic-carbon-containing feedstockcomprising free water, intercellular water, intracellular water,intracellular water-soluble salts, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, andmicrofibrils within fibrils; b. at least one reaction chamber comprisingat least one entrance passageway, at least one exit passageway forfluid, at least one exit passageway for processedorganic-carbon-containing feedstock, and at least three sections, thesections comprising, i. a wet fibril disruption section configured tointeract with at least some of the lignin and hemicellulose between thefibrils to make at least some regions of the cell wall more susceptibleto penetration by water-soluble salts, ii. a vapor explosion section incommunication with the wet fibril disruption section and at leastconfigured to volatilize plant fibril permeable fluid through rapiddecompression to penetrate the more susceptible regions of the cell wallso as to create a porous organic-carbon-containing feedstock with plantcell wall passageways for intracellular water and intracellularwater-soluble salts to pass from the plant cell, and iii. a compactionsection in communication with the vapor explosion section and configuredto compress the porous organic-carbon-containing feedstock betweenpressure plates configured to minimize formation of water-impermeablefelt so as to permit the escape of intracellular water and intracellularwater-soluble salt from the reaction chamber fluid exit passageway andto create processed organic-carbon-containing feedstock that passes outthrough its reaction chamber exit passageway; and c. a collection devicein communication with the reaction chamber and configured to gather theprocessed organic-carbon-containing feedstock having a water content ofless than 20% by weight and a water-soluble intracellular salt contentthat is decreased by at least 60% on a dry basis from that of theunprocessed organic-carbon-containing feedstock.
 3. The composition ofclaim 1 wherein the pelletizing sub-system, comprises: a compressionchamber configured to separate the processed organic-carbon-containingfeedstock into discrete units of mass having a longest length of atleast 0.16 inch (4.0 cm) and a density of at least 37.5 pounds per cubicfoot (0.60 grams per cubic centimeter) to form processed biomass pelletsand a collection chamber configured to gather an aggregate of processedbiomass pellets.
 4. The composition of claim 3 wherein the pelletizingsub-system, further comprises: a heating chamber configured to applysufficient heat to the processed organic-carbon-containing feedstock toreduce its water content to less than 10% by weight.
 5. The compositionof claim 4 wherein the compression chamber and the heating chamber arethe same chamber.
 6. The composition of claim 1 wherein thewater-soluble intracellular salt content is reduced by more than 70 wt%.
 7. The composition of claim 1 wherein the processedorganic-carbon-containing feedstock comprises less than 5 wt % water. 8.The composition of claim 1 wherein the processedorganic-carbon-containing feedstock comprises less than 5 wt %volatiles.
 9. The composition of claim 1, wherein the unprocessedorganic-carbon-containing feedstock comprises at least two from a groupconsisting of a herbaceous plant material, a soft woody plant material,and a hard woody plant material, wherein each type passes in seriesthrough the at least one reaction chamber, and wherein the energydensity of each plant material in the processedorganic-carbon-containing feedstock is at least 17 MMBTU/ton (20 GJ/MT).10. The composition of claim 1 wherein the unprocessedorganic-carbon-containing feedstock has a water-soluble salt content ofat least 4000 mg/kg on a dry basis.
 11. The composition of claim 1wherein the processed organic-carbon-containing feedstock has a watersoluble intracellular salt content that is decreased by more than 75 wt% on a dry basis from that of unprocessed organic-carbon-containingfeedstock and the compaction section of the beneficiated sub-system isconfigured to provide at least one rinsing step.
 12. The composition ofclaim 2, wherein the beneficiation system, further comprises: apretreatment chamber that is configured to use for each unprocessedorganic-carbon-containing feedstock a particular set of conditionsincluding time duration, temperature profile, and the chemical contentof pretreatment solution to at least initiate the dissolution ofcontaminates that would hinder creation of the plant cell wallpassageways that allow intracellular water and intracellularwater-soluble salts to pass outward from the plant cells.
 13. Thecomposition of claim 2, wherein the compaction section, furthercomprises: at least one rinsing subsection configured to flush more ofthe water-soluble salt from the porous organic-carbon-containingfeedstock before it is passed to the compaction section.
 14. Thecomposition of claim 2 wherein the vapor explosion section of thebeneficiation sub-system, further comprises: a wash element that isconfigured to remove and clean micro particles of unprocessedorganic-carbon-containing feedstock, lignin fragments, andhemicellulosic fragments from the vapor explosion section into a fine,sticky mass of biomass with high lignin content, and wherein a blendingchamber of the blending sub-section is further configured to receivefine, sticky mass of biomass to permit lower temperatures in acompaction chamber formation during formation of blended compactaggregates.
 15. A process of making processed biomass pellets,comprising the steps of: a. inputting into a system comprising a firstand a second subsystem an renewable unprocessedorganic-carbon-containing feedstock that includes free water,intercellular water, intracellular water, intracellular water-solublesalts, and at least some plant cells comprising cell walls that includelignin, hemicellulose, and microfibrils within fibrils, b. passingunprocessed organic-carbon-containing feedstock through the firstsub-system, a beneficiation sub-system process, to result in processedorganic-carbon-containing feedstock having a water content of less than20 wt % and a water soluble intracellular salt content that is reducedby at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of the unprocessedorganic-carbon-containing feedstock, and c. passing the processedorganic-carbon-containing feedstock through the second sub-system, apelletizing sub-system process, to result in processed biomass pellets,a solid renewable fuel composition having an energy density of at least17 MMBTU/ton (20 GJ/MT) a water content of less than 10 wt % andwater-soluble intracellular salt that is decreased by at least 60 wt %on a dry basis for the processed organic-carbon-containing feedstockfrom that of the unprocessed organic-carbon-containing feedstock, andmade with 40% less energy than expended to make current unprocessedbiomass pellets.
 16. The process of claim 14 wherein the beneficiationsub-system process and the pelletizing sub-system process, furthercomprises the steps of: a. inputting into a beneficiation sub-systemreaction chamber unprocessed organic-carbon-containing feedstockcomprising free water, intercellular water, intracellular water,intracellular water-soluble salts, and at least some plant cellscomprising cell walls that include lignin, hemicellulose, andmicrofibrils within fibrils; b. exposing the feedstock to hot solventunder pressure for a time at conditions specific to the feedstock tomake some regions of the cell walls comprising crystallized cellulosicfibrils, lignin, and hemicellulose more able to be penetrable bywater-soluble salts without dissolving more than 25 percent of thelignin and hemicellulose; c. removing the pressure so as to penetratethe more penetrable regions to create porous feedstock with open poresin the plant cell walls; and d. pressing the porous feedstock withconditions that include an adjustable compaction pressure versus timeprofile and compaction time duration, and between pressure platesconfigured to prevent felt from forming and blocking escape from thereaction chamber of intracellular and intercellular water, andintracellular water-soluble salts, and to create processedorganic-carbon-containing feedstock that has a water content of lessthan 20 wt % and a water-soluble intracellular salt content that isdecreased by at least 60 wt % on a dry basis for the processedorganic-carbon-containing feedstock from that of unprocessedorganic-carbon-containing feedstock; and the pelletizing sub-systemprocess, further comprises the steps of: e. a compressing the processedorganic-carbon-containing feedstock to separate it into pellets withdiscrete units of mass having a longest length of at least 0.16 inch(4.0 cm) and a density of at least 37.5 pounds per cubic foot (0.60grams per cubic centimeter) and collecting an aggregate of processedbiomass pellets.
 17. The process of claim 15 wherein the pelletizingsub-system process, further comprises the step of heating the processedorganic-carbon-containing feedstock to reduce its water content to lessthan 10% by weight.
 18. The process of claim 16 wherein the pelletizingsub-system process steps of compressing and heating are done at the sametime.
 19. The process of claim 15 wherein the beneficiation sub-systemprocess, further comprises: removing and cleaning of micro particles ofunprocessed organic-carbon-containing feedstock, lignin fragments, andhemicellulosic fragments from the vapor explosion section into a fine,sticky mass of biomass with high lignin content in the removing thepressure step, and the blending sub-system, further comprises: addingthe fine, sticky mass of biomass to the blended powder to permit lowertemperatures in the compressing step during formation of blended compactaggregates.
 20. The process of claim 14 wherein the beneficiationsub-system process and the pelletizing sub-system process, furthercomprises the steps of: a. inputting into a reaction chamber unprocessedorganic-carbon-containing feedstock comprising free water, intercellularwater, intracellular water, intracellular water-soluble salts, and atleast some plant cells comprising cell walls that include lignin,hemicellulose, and microfibrils within fibrils; b. exposing theunprocessed organic-carbon-containing feedstock to hot solvent underpressure for a time at conditions specific to the feedstock to make someregions of the cell walls comprising crystallized cellulosic fibrils,lignin, and hemicellulose more able to be penetrable by water-solublesalts without dissolving more than 25 percent of the lignin andhemicellulose; c. removing the pressure so as to penetrate the morepenetrable regions to create porous feedstock with open pores in theplant cell walls; and d. pressing the porous feedstock under conditionsthat include an adjustable compaction pressure versus time profile andcompaction time duration, and between pressure plates configured toprevent felt from forming and blocking escape from the reaction chamberof intracellular and intercellular water, and intracellularwater-soluble salts and to create processed organic-carbon-containingfeedstock that has a water content of less than 20 wt %, a water-solubleintracellular salt content that is decreased by at least 60 wt % on adry basis over that of unprocessed organic-carbon-containing feedstock,and a cost per weight of removing the water and water-soluble salt thatis reduced to less than 60% of the cost per weight of similar waterremoval from known mechanical, known physiochemical, or known thermalprocesses, and the pelletizing sub-system process, further comprises thestep of: e. a compressing the processed organic-carbon-containingfeedstock to separate it into pellets with discrete units of mass havinga longest length of at least 0.16 inch (4.0 cm) and a density of atleast 37.5 pounds per cubic foot (0.60 grams per cubic centimeter) andcollecting an aggregate of processed biomass pellets.